Filling Devices, Systems And Methods For Transferring Hazardous Waste Material Into A Sealable Container

ABSTRACT

The present invention provides systems, methods and devices for storing and/or disposing of hazardous waste material such as calcined material. In certain embodiments, the system comprises a filling nozzle having a valve body having a distal end and an outer surface, the outer surface proximate the distal end being configured to sealingly and removeably couple to an inner surface of a filling port of the container. In certain embodiments, the method comprises (a) coupling an outer surface of a filling nozzle with an inner surface of a filling port of a container to form a first seal (b) adding hazardous waste material into the container (c) decoupling the filling port from the filling nozzle and (d) inserting a fill plug into the filling port, the fill plug forming a second seal with the inner surface of the filling port, the second seal being distally spaced from at least a portion of the first seal with respect to the container.

BACKGROUND OF THE INVENTION

The present invention generally relates to systems, methods andcontainers for storing hazardous waste material and, more particularly,filling devices, systems and methods for transferring hazardous wastematerial into a sealable container.

Despite a proliferation of systems for handling and storing hazardouswaste materials, prior art systems are still unable to effectivelyconfine and control the unnecessary spread of hazardous wastecontamination to areas remotely located from the hazardous wastematerial filling stations. Therefore, an urgent need exists forhazardous waste processing/storing systems that effectively minimizeand/or eliminate unnecessary hazardous material contamination.

BRIEF SUMMARY OF THE INVENTION

In some embodiments, there are systems, methods and devices for storingand/or disposing of hazardous waste material. In some embodiments, thehazardous waste material includes nuclear waste such as calcinedmaterial.

In one embodiment, there is system for transferring hazardous wastematerial into a sealable container, the system includes a filling nozzlehaving (a) a valve body having a distal end and an outer surface, thevalve body including a valve seat proximate the distal end, the outersurface proximate the distal end being configured to sealingly andremoveably couple the valve body to an inner surface of a filling portof the container, (b) a valve head having a valve face configured toform a seal with the valve seat in a closed configuration, the valvehead configured to allow the valve body and the container to be fluidlycoupled with one another in an open configuration, and (c) a valve stemextending axially from the valve head through at least a portion of thevalve body. In a further embodiment, the system includes a containerconfigured to sealingly contain the hazardous waste material, thecontainer including the filling port. In a further embodiment, thesystem includes a hopper, a first scale coupled to the hopper andconfigured to determine an initial hopper weight, a second scale coupledto the container and configured to determine a container fill weight,and a processor coupled to the first scale and the second scale andconfigured to compare the initial hopper weight to the container fillweight.

In one embodiment, the hopper includes a volume substantially equal to avolume of the container. In a further embodiment, the system includes atleast one vibrator coupled to the hopper. In a further embodiment, thesystem includes at least one vibrator coupled to a bottom of thecontainer. In a further embodiment, the system includes at least onevibrator coupled to a sidewall of the container. In a furtherembodiment, the system includes a lift mechanism configured to lift thecontainer toward the fill nozzle.

In one embodiment, the lift mechanism including at least one damper. Ina further embodiment, the system includes a sensor disposed in the valvehead. In one embodiment, the sensor is configured to determine a levelof hazardous material in the container. In one embodiment, the sensorextends distally from the valve body. In one embodiment, the sensor iscoupled to a wire that extends through the valve stem. In oneembodiment, the valve body includes a first branch section configured tocouple to a hopper, and a second branch section including the distal endand having a proximal end, the proximal end coupled to a drive mechanismconfigured to move the valve stem. In one embodiment, the drivemechanism includes a pneumatic cylinder. In one embodiment, the valvestem extends through the proximal end of the second branch section, theproximal end including a seal coupled to a portion of the valve stem. Ina further embodiment, the system includes a vacuum nozzle configured tobe in fluid communication with the container. In one embodiment, thevacuum nozzle extends through the distal end of the valve body. In oneembodiment, the vacuum nozzle includes a filter proximate the distal endof the valve body.

In one embodiment, the container includes an exhaust port. In oneembodiment, the exhaust port includes a filter. In a further embodiment,the system includes a vacuum nozzle sealingly and removeably couplablewith the exhaust port, the vacuum nozzle being in sealed fluidcommunication with the valve body in a filling configuration. In oneembodiment, the outer surface proximate the distal end includes at leastone seal. In one embodiment, the at least one seal includes at least oneo-ring. In one embodiment, the valve head extends distally from thevalve body and into the container in the open configuration. In oneembodiment, the container is at least initially under negative pressure.In one embodiment, the filling port of the container is configured to besealed closed after decoupling the valve body from the filling port.

In another embodiment, there is a method of transferring hazardous wastematerial into a sealable container, the method comprising (a) couplingan outer surface of a filling nozzle with an inner surface of a fillingport of a container to form a first seal, (b) opening a valve of afilling nozzle to add hazardous waste material into the container, thevalve being proximate the first seal, (c) closing the valve of thefilling nozzle, (d) decoupling the filling port from the filling nozzleand (e) inserting a fill plug into the filling port, the fill plugforming a second seal with the inner surface of the filling port, thesecond seal being distally spaced from at least a portion of the firstseal with respect to the container. In one embodiment, the valveincludes, a valve body having a distal end and an outer surface, thevalve body including a valve seat proximate the distal end, the outersurface proximate the distal end being configured to sealingly andremoveably couple the valve body to the filling port of the container, avalve head having a valve face configured to form a seal with the valveseat in a closed configuration, the valve head configured to allow thevalve body and the container to be fluidly coupled with one another inan open configuration, and a valve stem extending axially from the valvehead through at least a portion of the valve body.

In one embodiment, the container includes an evacuation port. In oneembodiment, the evacuation port includes an evacuation plug threadablycoupled to the evacuation port and the method further comprises (f)allowing air and/or gas to pass through the filter and between theevacuation plug and the evacuation port in a filling configuration and aheating configuration, and (g) closing the evacuation port with theevacuation plug in a closed configuration. In one embodiment, theevacuation port includes a filter. In a further embodiment, the methodincludes drawing air within the container displaced by the hazardousmaterial through an evacuation nozzle coupled to the container, theevacuation nozzle being in sealed fluid communication with the valvebody via the container.

In a further embodiment, the method includes lifting the containertoward the filling nozzle via a lifting mechanism to couple the fillingport and the filling nozzle. In a further embodiment, the methodincludes (t) weighing a hopper containing the hazardous material todetermine an initial hopper weight, (g) weighing the container whileadding the hazardous material to determine a container fill weight, and(h) comparing, via a processor, the difference between the initialhopper weight to the container fill weight. In a further embodiment, themethod includes closing the valve once the container fill weight equalsthe initial hopper weight. In a further embodiment, the method includesvibrating the hopper via at least one vibrator while adding thehazardous material to the container. In a further embodiment, the methodincludes, vibrating the container via at least one vibrator coupled tothe container while adding the hazardous material to the container. In afurther embodiment, the method includes measuring the level of hazardousmaterial in the container via a sensor disposed in the valve head.

In one embodiment, wherein the first seal includes at least one o-ring.In one embodiment, the second seal includes a gasket, the gasket beingcomprised of one or more of metal, ceramic or graphite. In a furtherembodiment, the method includes applying a vacuum to the containerbefore or during adding of the hazardous material. In a furtherembodiment, the method includes (f) permanently sealing the fill plug tothe filling port, and (g) heating and reducing the volume of thecontainer after permanently sealing the fill plug to the filling port.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofembodiments of the systems, methods and containers for storing hazardouswaste material, will be better understood when read in conjunction withthe appended drawings of exemplary embodiments. It should be understood,however, that the invention is not limited to the precise arrangementsand instrumentalities shown.

In the drawings:

FIG. 1A is a perspective view of a known container shown prior to a HIPprocess;

FIG. 1B is a perspective view of the container of FIG. 1A shown afterthe HIP process;

FIG. 2 is a schematic flow diagram of a process for storing hazardouswaste in accordance with an exemplary embodiment of the presentinvention;

FIG. 3 is a side partial cross sectional elevational view of a modularsystem in accordance with an exemplary embodiment of the presentinvention;

FIG. 4 is a top planar view of the modular system of FIG. 3 shown withthe top partially removed;

FIG. 5A is a perspective view of a container having fill and evacuationports in accordance with an exemplary embodiment of the presentinvention;

FIG. 5B is a perspective view of a container having a single port inaccordance with an exemplary embodiment of the present invention;

FIG. 6A is a side cross sectional view of a top portion of the containershown in FIG. 5A;

FIG. 6B is a side cross sectional view of a top portion of the containershown in FIG. 5B;

FIG. 7 is a front perspective view of a first cell of the exemplarymodular system of FIGS. 3 and 4 with the front wall removed;

FIG. 8 is a partial cross sectional view of a filling system for usewithin the first cell of FIG. 7 shown with the single port container ofFIG. 5B;

FIG. 9 is a partial cross sectional view of a filling system for usewithin the first cell of FIG. 7 shown with the dual port container ofFIG. 5A;

FIG. 10 is a partial cross sectional view of a filling nozzle inaccordance with an exemplary embodiment of the present invention;

FIG. 11 is a schematic diagram of a filling-weigh system in accordancewith an exemplary embodiment of the present invention;

FIG. 12 is a partial side perspective schematic diagram of the first andsecond cells of FIG. 3;

FIG. 13 is a partial side cross sectional view of a vacuum nozzlecoupled to the container shown in FIG. 5B;

FIG. 14 is a perspective view of an orbital welder in use with thecontainer shown in FIG. 5B;

FIG. 15 is a top perspective view of a second cell of the exemplarymodular system of FIGS. 3 and 4 with the top and side walls partiallyremoved;

FIG. 16 is a top perspective view of a third cell of the exemplarymodular system of FIGS. 3 and 4 with the top and side walls partiallyremoved; and

FIG. 17 is a side perspective view of a fourth cell of the exemplarymodular system of FIGS. 3 and 4 with the top and side walls partiallyremoved.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the various embodiments of thepresent disclosure, examples of which are illustrated in theaccompanying drawings FIGS. 2-17. Wherever possible, the same referencenumbers will be used throughout the drawings to refer to the same orlike parts.

Nuclear waste, such as radioactive calcined material, can be immobilizedin a container that allows the waste to be safely transported in aprocess known as hot isostatic pressing (HIP). In general, this processinvolves combining the waste material in particulate or powdered formwith certain minerals and subjecting the mixture to high temperature andhigh pressure to cause compaction of the material.

In some instances, the HIP process produces a glass-ceramic waste formthat contains several natural minerals that together incorporate intotheir crystal structures nearly all of the elements present in HLWcalcined material. The main minerals in the glass-ceramic can include,for example, hollandite (BaAl₂Ti₆O₁₆), zirconolite (CaZrTi₂O₇), andperovskite (CaTiO₃). Zirconolite and perovskite are the major hosts forlong-lived actinides, such as plutonium, though perovskite principallyimmobilizes strontium and barium. Hollandite principally immobilizescesium, along with potassiume, rubidium, and barium.

Treating radioactive calcined material with the HIP process involves,for example, filling a container with the calcined material andminerals. The filled container is evacuated and sealed, then placed intoa HIP furnace, such as an insulated resistance-heated furnace, which issurrounded by a pressure vessel. The vessel is then closed, heated, andpressurized. The pressure is applied isostatically, for example, viaargon gas, which, at pressure, also is an efficient conductor of heat.The combined effect of heat and pressure consolidates and immobilizesthe waste into a dense monolithic glass-ceramic sealed within thecontainer.

FIGS. 1A and 1B respectively show an example container, generallydesignated 100, before and after HIP processing. Container 100 has abody 110 defining an interior volume for containing waste material. Body110 includes sections 112 each having a first diameter and a section 114having a second diameter that may be less than the first diameter.Container 100 further has a lid 120 positioned at a top end of body 110and a tube 140 extending from lid 120 which communicates with theinterior volume of body 110. The interior volume of body 110 is filledwith waste material via tube 140.

Following hot isostatic pressing, as shown in FIG. 1B, the volume ofbody 110 is substantially reduced and container 100 is then sealed.Typically, tube 140 is crimped, cut, and welded by linear seam welding.One drawback in such a process is that cutting of tube 140 can createsecondary waste as the removed portion of tube 140 may contain amountsof residual waste material which must then be disposed of in a propermanner. Moreover, the tools used for cutting tube 140 may be exposed tothe residual waste material and/or require regular maintenance orreplacement due to wear. Also, this system requires complex mechanicalor hydraulic systems to be in the hot cell (radioactive environment)near the can to be sealed reducing the life of seals on hydraulic ramsand the equipment is bulky taking up additional space in the hot cell.It is therefore desirable to have systems, methods, filling equipmentand containers for storing hazardous waste material that can avoid oneor more of these drawbacks.

FIG. 2 schematically represents an exemplary process flow 200 used todispose of nuclear waste, such as calcined material, in accordance withthe present invention. Process 200 may be performed using a modularsystem 400, exemplary embodiments of which are illustrated in subsequentfigures, wherein the hazardous waste is processed or moved in a seriesof isolated cells. Modular system 400 may be referred to as includingthe “hot cell” or “hot cells”. In some embodiments, each cell isisolated from the outside environment and other cells such that anyspillage of hazardous waste may be contained within the cell in whichthe spill occurred.

Modular system 400 in accordance with the present invention may be usedto process liquid or solid hazardous waste material. The hazardous wastematerial may be a radioactive waste material. A radioactive liquid wastemay include aqueous wastes resulting from the operation of a first cyclesolvent extraction system, and/or the concentrated wastes fromsubsequent extraction cycles in a facility for reprocessing irradiatednuclear reactor fuels. These waste materials may contain virtually allof the nonvolatile fission products, and/or detectable concentrations ofuranium and plutonium originating from spent fuels, and/or all actinidesformed by transmutation of the uranium and plutonium as normallyproduced in a nuclear reactor. In one embodiment, the hazardous wastematerial includes calcined material.

Modular system 400 may be divided into two or more cells. In oneembodiment, modular system 400 includes at least four separate cells. Inone embodiment, modular system 400 includes four separate cells. In onesuch embodiment, the series of cells include a first cell 217, which maybe a filling cell, a second cell 218, which may be a bake-out and vacuumscaling cell, a third cell 232 which may be a process cell, and a fourthcell 230 which may be a cooling and packaging cell, each of which willbe discussed in more detail below.

In one embodiment, first cell 217 includes a feed blender 212 configuredto mix a hazardous waste material with one or more additives. In oneembodiment, a container feed hopper 214 is coupled to feed blender 212.In one embodiment, container feed hopper 214 is coupled with a fillsystem to transfer the hazardous waste material and additive mixtureinto container 216. In some embodiments, calcined material istransferred from a surge tank 205 to a calcined material receipt hopper207 configured to supply feed blender 212. In some embodiments,additives are supplied to feed blender 212 from hopper 210. In someembodiments, the additives are transferred to hopper 210 from tank 201.

After being filled, container 216 is removed from first cell 217 andtransferred to second cell 218 where bake-out and vacuum sealing stepstake place. In some embodiments, the bake-out process includes heatingcontainer 216 in a furnace 290 to remove excess water, for example, at atemperature of about 400° C. to about 500° C. In some embodiments,off-gas is removed from container 216 during the bake-out process androuted through line 206, which may include one or more filters 204 ortraps 219 to remove particulates or other materials. In furtherembodiments, a vacuum is established in container 216 during thebake-out process and container 216 is sealed to maintain the vacuum.

After the bake-out and sealing steps, according to some embodiments,container 216 is transferred to third cell 232 where the container 216is subjected to hot isostatic pressing or HIP, for example, at elevatedtemperature of 1000° C.-1250° C. and elevated argon pressure suppliedfrom a compressor 234 and argon source 236. In some embodiments, hotisostatic pressing results in compaction of container 216 and the wastematerial contained therein. After the hot isostatic pressing, accordingto some embodiments, container 216 is transferred to fourth cell 230 forcooling and/or packaging for subsequent loading 203 for transport andstorage.

Modular system 400 may be configured in numerous ways depending on thespatial arrangement of the plurality of cells. In an embodiment, theplurality of cells may have any suitable spatial arrangement, includinga lateral arrangement of cells, a vertical arrangement of cells or acombination of laterally arranged cells and vertical arranged cells. Inone embodiment, modular system 400 comprises a plurality of cellsspatially arranged in a single row of contiguous cells, wherein eachcell is isolated from an adjacent cell. In another embodiment, theplurality of cells may be spatially arranged in a single row ofcontiguous cells, wherein each cell may be isolated from an adjacentcell by at least one common side wall. In another embodiment, theplurality of cells may be arranged vertically in space in single columnof contiguous cells, wherein each cell is isolated from an adjacent cellby at least one common wall. In yet another embodiment, the plurality ofcells may be spatially arranged in a plurality of rows of contiguouscells.

In one embodiment, modular system 400 includes a first cell 217, asecond cell 218, and a third cell 232, first cell 217 being adjacentsecond cell 218 and contiguous therewith, and third cell 232 beingadjacent to second cell 218 and being contiguous therewith, whereinfirst cell 217, second cell 218 and third cell 232 are spatiallyarranged in a single row of cells.

Modular system 400 may contain one or more assembly lines that movecontainers 216 sequentially through modular system 400. As illustratedin FIGS. 2-4, an exemplary modular system 400 for processing and/orstoring and/or disposing of a hazardous waste material includes parallelassembly lines of a plurality of cells for manipulating container 216.

In some embodiments, as described above, the plurality of cells formanipulating container 216 includes at least first cell 217, second cell218, third cell 232 and fourth cell 230. In other embodiments, anynumber of cells may be provided. In some embodiments, the cells may beheld at different pressures relative to adjacent cells to controlcontamination from spreading between cells. For example, each subsequentcell may have a higher pressure than the previous cell such that any airflow between cells flows toward the beginning of the process. In someembodiments, first cell 217 is held at a first pressure P1 and secondcell 218 is held at a second pressure P2. In one embodiment, firstpressure P1 is less than second pressure P2. In such embodiments, firstcell 217 does not exchange air with second cell 218 at least during thetime when container 216 is being manipulated in first cell 217. Inanother such embodiment, an air interlock 241 (see FIG. 12), asdescribed in further detail below, couples first cell 217 to second cell218 and is configured to allow transfer of container 216 from first cell217 to second cell 218 while maintaining at least one seal between firstcell 217 and second cell 218. In another embodiment, first cell 217 isheld at first pressure P1, second cell is held at second pressure P2 andthird cell 232 is held at a third pressure P3, where third pressure P3is greater than second pressure P2 which is greater than first pressureP1. In such embodiments, third cell 232 is isolated from first cell 217and second cell 218, wherein second cell 218 and third cell 232 areconfigured to allow transfer of container 216 from second cell 218 tothird cell 232. In yet another embodiment, first cell 217 is held atfirst pressure P1, second cell 218 is held at second pressure P2, thirdcell 232 is held at third pressure P3 and fourth cell 230 is held at afourth pressure P4, wherein fourth pressure P4 is greater than thirdpressure P3, third pressure P3 is greater than second pressure P2 whichis greater than first pressure P1. In such embodiments, fourth cell 230is isolated from first cell 217, second cell 218 and third cell 232,wherein third cell 232 and fourth cell 230 are configured to allowtransfer of container 216 from third cell 232 to the fourth cell 230. Inone embodiment, each pressure P1, P2, P3 and/or P4 is negative relativeto normal atmospheric pressure. In some embodiments, the pressuredifference between first cell 217 and second cell 218 is about 10 KPa toabout 20 KPa. In some embodiments, the pressure difference betweensecond cell 218 and third cell 232 is about 10 KPa to about 20 KPa. Insome embodiments, the pressure difference between third cell 232 andfourth cell 230 is about 10 KPa to about 20 KPa.

I. First Cell

Exemplary embodiments of first cell 217 are illustrated in FIGS. 3, 4and 7. In one embodiment, first cell 217 is a filling cell which allowsfor filling a container 216 with hazardous waste with minimalcontamination of the exterior of container 216. In one embodiment, emptycontainers 216 are first introduced into the modular system 400. In oneembodiment, empty containers 216 are placed in first cell 217 and firstcell 217 is sealed before transferring any hazardous waste materialwithin first cell 217. In one embodiment, once first cell 217 is scaledand contains one or more empty containers 216, first cell 217 is broughtto pressure P1.

Container and Method of Filling a Container

Containers of various designs may be used in accordance with the variousembodiments of the present disclosure. A schematic container 216, whichmay be a HIP can, is shown throughout in FIGS. 2, 3, 4, 7, 13, 15, 16and 17. Container 216 may have any suitable configuration known in theart for HIP processing. In some embodiments, container 216 is providedwith a single port. In other embodiments, container 216 is provided witha plurality of ports. Some particular configurations for containers 216that may be used in accordance with the various embodiments of thepresent invention are shown in FIGS. 5A, 5B, 6A and 6B, which illustrateexemplary containers configured to sealingly contain hazardous wastematerial in accordance with the present disclosure.

FIGS. 5A and 6A show one embodiment of a container, generally designated500, for containment and storage of nuclear waste materials or otherdesired contents in accordance with an exemplary embodiment of thepresent invention. Container 500, in some embodiments, is particularlyuseful in HIP processing of waste materials. It should however beunderstood that container 500 can be used to contain and store othermaterials including nonnuclear and other waste materials.

According to some embodiments, container 500 generally includes body510, lid 520, filling port 540, and evacuation port 560. In someembodiments, container 500 also includes filling plug 550 configured toengage with filling port 540. In further embodiments, container 500 alsoincludes evacuation plug 570 configured to engage with evacuation port560. In yet further embodiments, container 500 includes lifting member530.

Body 510 has a central longitudinal axis 511 and defines interior volume516 for containing nuclear waste materials or other materials accordingto certain embodiments of the invention. In some embodiments, a vacuumcan be applied to interior volume 516. In some embodiments, body 510 hasa cylindrical or a generally cylindrical configuration having closedbottom end 515. In some embodiments, body 510 is substantially radiallysymmetric about central longitudinal axis 511. In some embodiments, body510 may be configured to have the shape of any of the containersdescribed in U.S. Pat. No. 5,248,453, which is incorporated herein byreference in its entirety. In some embodiments, body 510 is configuredsimilarly to body 110 of container 100 shown in FIG. 1. Referring toFIG. 5A, in some embodiments body 510 has one or more sections 512having a first diameter alternating along central longitudinal axis 511with one or more sections 514 having a smaller second diameter. Body 510may have any suitable size. In some embodiments, body 510 has a diameterin a range of about 60 mm to about 600 mm. In some embodiments, body 510has a height in a range of about 120 mm to about 1200 mm. In someembodiments, body 510 has a wall thickness of about 1 mm to about 5 mm.

Body 510 may be constructed from any suitable material known in the artuseful in hot isostatic pressing of nuclear waste materials. In someembodiments, body 510 is constructed of material capable of maintaininga vacuum within body 500. In some embodiments, body 510 is constructedfrom a material that is resistant to corrosion. In some embodiments,body 510 is made from a metal or metal alloy, for example, stainlesssteel, copper, aluminum, nickel, titanium, and alloys thereof.

In some embodiments, container 500 includes a lid 520 opposite closedbottom end 515. Lid 520, in some embodiments, is integrally formed withbody 510. In other embodiments, lid 520 is formed separately from body510 and secured thereto, for example, via welding, soldering, brazing,fusing or other known techniques in the art to form a hermetic sealcircumferentially around lid 520. In some embodiments, lid 520 ispermanently secured to body 510. Referring to FIG. 6A, lid 520 includesinterior surface 524 facing interior volume 516 and exterior surface 526opposite interior surface 524. In some embodiments, central longitudinalaxis 511 is substantially perpendicular to interior surface 524 andexterior surface 526. In some embodiments, central longitudinal axis 511extends through a center point of interior surface 524 and exteriorsurface 526. In some embodiments, container 500 further includes aflange 522 surrounding exterior surface 526.

In some embodiments, container 500 further includes a filling port 540having an outer surface 547, an inner surface 548 defining a passagewayin communication with interior volume 516, and configured to couple witha filling nozzle. In some embodiments, the nuclear waste material to becontained by container 500 is transferred into interior volume 516through filling port 540 via the filling nozzle. In some embodiments,filling port 540 is configured to at least partially receive the fillingnozzle therein. In some embodiments, inner surface 548 of filling port540 is configured to form a tight seal with a filling nozzle so as toprevent nuclear waste material from exiting interior volume 516 betweeninner surface 548 of filling port 540 and the filling nozzle duringfilling of container 500.

Filling port 540 may extend from lid 520 as shown in the exemplaryembodiment of FIGS. 5A and 6A. In some embodiments, filling port 540 maybe integrally formed with lid 520. In other embodiments, filling port540 is formed separately from lid 520 and secured thereto, for example,by welding. In some embodiments, filling port 540 is constructed frommetal or metal alloy, and may be made from the same material as body 510and/or lid 520.

Referring particularly to FIG. 6A, filling port 540 has a generallytubular configuration with inner surface 548 extending from first end542 towards second end 543. According to some embodiments, filling port540 extends from lid 520 along an axis 541 substantially parallel tocentral longitudinal axis 511. In some embodiments, inner surface 548 isradially disposed about axis 541. In some embodiments, first end 542 offilling port 540 defines an opening in lid 520 and has an internaldiameter Df1. In some embodiments, second end 543 of filling port 540has an internal diameter Df2 which may be different than diameter Df1.In some embodiments, Df2 is larger than Df1. In one embodiment, forexample, Df1 is about 33 mm and Df2 is about 38 mm. In some embodiments,a stepped portion 549 is provided on the exterior of filling port 540.In some embodiments, stepped portion can be used for positioning anorbital welder (e.g., orbital welder 242 described herein below).

Container 500, in some embodiments, further includes a filling plug 550configured to couple with filling port 540. In some embodiments, fillingplug 550 is configured and dimensioned to be at least partially receivedin filling port 540 as generally shown in FIG. 6A. In some embodiments,filling plug 550 is radially disposed about axis 541 when coupled withfilling port 540. In some embodiments, filling plug 550 is configured toclose and seal filling port 540 to prevent material from exitinginterior volume 516 via filling port 540.

Filling plug 550, in some embodiments, is configured to abut innersurface 548 when coupled to filling port 540. In some embodiments,filling plug 550 includes a portion having a diameter substantiallyequal to an internal diameter of filling port 540. In some embodiments,filling plug 550 includes a first portion 552 having a diametersubstantially equal to Df1. In some embodiments, filling plug 550alternatively or additionally includes a second portion 553 having adiameter substantially equal to Df2. In some embodiments, second portion553 is configured to abut surface 544 when filling plug 550 is coupledwith filling port 540. In some embodiments, filling plug 550 furtherabuts end surface 545 when filling plug 550 is coupled with filling port540.

In some embodiments, filling plug 550 when coupled with filling port 540creates a seam 546. In some embodiments, seam 546 is formed at aninterface between filling plug 550 and end surface 545 of second end 543of filling port 540. In some embodiments, seam 546 is located betweenexternal surface 551 of filling plug 550 and external surface 547 offilling port 540. In some embodiments, external surface 551 of fillingplug 550 is substantially flush with external surface 547 of fillingport 540 proximate seam 546. Seam 546 extends circumferentially around aportion of filling plug 550 according to some embodiments.

Filling port 540 and filling plug 550 may be secured together accordingto some embodiments by any suitable method known in the art. In someembodiments, filling plug 550 is threadably coupled with filling port540. According to some of these embodiments, at least a portion of innersurface 548 is provided with internal threads that are configured toengage with external threads provided on at least a portion of fillingplug 550 such that, for example, filling plug 550 may be screwed intofilling port 540. In some embodiments, one or more of portions 552 and553 may be provided with external threads that engage with internalthreads provided on inner surface 548 of filling port 540. In otherembodiments, filling port 540 and filling plug may be coupled via aninterference or friction fit. In some embodiments, container 500includes a gasket (not shown) positioned within filling port 540 to aidin sealing filling port 540 with filling plug 550. In some embodiments,a gasket is positioned between filling plug 550 and surface 544

In some embodiments, filling port 540 and filling plug 550 may bepermanently secured together after filling of container 500 with thenuclear waste material or other desired contents. In some embodiments,filling port 540 and filling plug 550 may be mechanically securedtogether. In some embodiments, filling port 540 may be fused withfilling plug 550. In some embodiments, filling port 540 and filling plug550 may be soldered or brazed together. In some embodiments, fillingport 540 and filling plug 550 may be welded together along seam 546, forexample, by orbital welding. In other embodiments, an adhesive or cementmay be introduced into seam 546 to seal filling port 540 and fillingplug 550 together.

In some embodiments, container 500 includes an evacuation port 560having an outer surface 567 and an inner surface 568 defining apassageway in communication with interior volume 516. In someembodiments, evacuation port 560 is configured to allow venting of airor other gas from interior volume 516. In some embodiments, evacuationport 560 is configured to couple with an evacuation nozzle, as describedfurther below, for evacuating air or other gas from interior volume 516.In some embodiments, the evacuation nozzle is connected with aventilation or vacuum system capable of drawing air or other gas frominterior volume 516 through evacuation port 560.

Evacuation port 560 may extend from lid 520 as shown in the exemplaryembodiment of FIGS. 5A and 6A. In some embodiments, evacuation port 560may be integrally formed with lid 520. In other embodiments, evacuationport 560 is formed separately from lid 520 and secured thereto, forexample, by welding, soldering, brazing, or the like. In someembodiments, evacuation port 560 is constructed from metal or metalalloy, and may be made from the same material as body 510 and/or lid520.

Referring particularly to FIG. 6A, evacuation port 560 has a generallytubular configuration with inner surface 568 extending from first end562 towards second end 563. According to some embodiments, evacuationport 560 extends from lid 520 along an axis 561 substantially parallelto central longitudinal axis 511. In some embodiments, axis 561 iscoplanar with central longitudinal axis 511 and axis 541 of filling port540. In some embodiments, inner surface 568 is radially disposed aboutaxis 561. In some embodiments, first end 562 of evacuation port 560defines an opening in lid 520 and has an internal diameter D_(e1). Insome embodiments, second end 563 of evacuation port 560 has an internaldiameter D_(e2) which may be different than diameter D_(e1). In someembodiments, D_(e2) is larger than D_(e1). In some embodiments,evacuation port 560 may further include one or more intermediatesections positioned between first end 562 and second end 563 defininginternal diameters different than D_(e1) and D_(e2). In the exemplaryembodiment shown in FIG. 6A, evacuation port 562 includes intermediatesections 564 and 565 respectively have internal diameters D_(e3) andD_(e4) and configured such that D_(e1)<D_(e3)<D_(e4)<D_(e2). In someembodiments, evacuation port 560 has the same external diameter asfilling port 540. In some embodiments, a stepped portion 569 is providedon the exterior of evacuation port 560. In some embodiments, steppedportion 569 can be used for positioning an orbital welder (e.g. orbitalwelder 242 described therein below). In some embodiments, steppedportion 569 can be used for positioning the evacuation nozzle.

According to some embodiments of the invention, evacuation port 560 isprovided with a filter 590. In some embodiments, filter 590 is sized tospan across the passageway defined by evacuation port 560. In someembodiments, filter 590 is positioned within evacuation port 560 at orproximate to first end 562 and has a diameter substantially equal toD_(e1). In some embodiments, the filter 590 is sealingly engaged toinner surface 568 of evacuation port 560. In some embodiments, thefilter 590 is secured to inner surface 568 of evacuation port 560, forexample, via welding, soldering, brazing, or the like. In oneembodiment, filter 590 is a high efficiency particulate air (HEPA)filter. In some embodiments, filter 590 is a single layer of material.In some embodiments, filter 590 is multi-layer material. In someembodiments, filter 590 is made from sintered material. In someembodiments, filter 590 is made from metal or metal alloy, for example,stainless steel, copper, aluminum, iron, titanium, tantalum, nickel, andalloys thereof. In some embodiments, filter 590 is made from a ceramic,for example, aluminum oxide (Al₂O₃) and zirconium oxide (ZrO₂). In someembodiments, filter 590 includes carbon or a carbon compound, forexample, graphite. In some embodiments, the material of filter 590 ischosen so that upon heating the filter densifies into a solid andnon-porous material. In some embodiments, the material of filter 590 ischosen wherein at a first temperature filter 590 is porous to air and/orgas but prevents passage of particles and at a second temperature filter590 densifies into a non-porous material, wherein the second temperatureis greater than the first temperature.

In some embodiments, filter 590 is configured to prevent passage ofparticles having a predetermined dimension through evacuation port 560while allowing passage of air or other gas. In some embodiments, filter590 is configured to prevent passage of particles having a dimensiongreater than 100 μm through evacuation port 560. In some embodiments,filter 590 is configured to prevent passage of particles having adimension greater than 75 μm through evacuation port 560. In someembodiments, filter 590 is configured to prevent passage of particleshaving a dimension greater than 50 μm through evacuation port 560. Insome embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 25 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 20 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 15 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 12 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 10 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 8 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 5 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 1 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 0.5 μm through evacuation port560. In some embodiments, filter 590 is configured to prevent passage ofparticles having a dimension greater than 0.3 μm through evacuation port560.

Container 500, in some embodiments, further includes an evacuation plug570 configured to couple with evacuation port 560. In some embodiments,evacuation plug 570 is configured and dimensioned to be at leastpartially received in evacuation port 560 as generally shown in FIG. 6A.In some embodiments, evacuation plug 570 is radially disposed about axis561 when coupled with filling port 560. In some embodiments, evacuationplug 570 is configured to allow air and/or other gas to pass throughevacuation port 560 in a filling configuration and to close fillingevacuation port 560 in a closed configuration to prevent air and/orother gas from passing through evacuation port 560.

In some embodiments, evacuation plug 570 includes a portion having adiameter substantially equal to or slightly less than an internaldiameter of evacuation port 560. In some embodiments, evacuation plug570 includes a first portion 572 having a diameter substantially equalto or slightly less than D_(e1). In some embodiments, evacuation plug570 alternatively or additionally includes a second portion 573 having adiameter substantially equal to D_(e2). In some embodiments, evacuationplug 570 alternatively or additionally includes intermediate portions574 and 575 having respective diameters substantially equal to orslightly less than D_(e3) and D_(e4).

In some embodiments, evacuation plug 570 when coupled with evacuationport 550 creates a seam 566. In some embodiments, seam 566 is formed atan interface between evacuation plug 570 and second end 563 ofevacuation port 560. In some embodiments, seam 566 is located betweenexternal surface 571 of evacuation plug 570 and external surface 567 ofevacuation port 560. In some embodiments, external surface 571 ofevacuation plug 570 is substantially flush with external surface 567 ofevacuation port 560 proximate seam 566. Seam 566 extendscircumferentially around a portion of evacuation plug 570 according tosome embodiments.

According to some embodiments of the invention, evacuation plug 570 isconfigured to be at least partially received within evacuation port 560in a filling configuration such that air and/or other gas is allowed toexit from interior volume 516 of container 500 through filter 590 andthrough evacuation port 560 between inner surface 568 of evacuation port560 and evacuation plug 570. In some embodiments, evacuation plug 570and evacuation port 560 are coupled in the filling configuration suchthat a gap 582 of sufficient dimension to allow for air and/or other gasto pass there through is maintained between evacuation plug 570 andevacuation port 560 to provide a pathway for air and/or other gas toevacuated from interior volume 516. In some embodiments, gap 582 extendscircumferentially around at least a portion of evacuation plug 570. Insome embodiments, air and/or other gas is allowed to pass through gap582 and through seam 566 in the filling configuration. In someembodiments, evacuation plug 570 and evacuation port 560 are coupled inthe filling configuration such that a space 581 is maintained betweenevacuation plug 570 and filter 590. When present, space 581 should be ofsufficient distance along the axial direction (e.g., along axis 561) toallow for air and/or other gas to pass through filter 590.

In some embodiments, container 500 is further configured to transitionfrom the filling configuration to a closed configuration wherein theevacuation plug 570 is coupled with evacuation port 560 such that airand/or other gas is not allowed to pass through evacuation port 560. Insome embodiments, evacuation port 560 is hermetically sealed by theevacuation plug 570 in the closed configuration. In some embodiments,the closed configuration allows a vacuum to be maintained in interiorvolume 516. In some embodiments, in the closed configuration, evacuationplug 570 is at least partially received within evacuation port 560 toclose and seal the passageway defined by evacuation port 560 to preventmaterial from passing therethrough.

In some embodiments, a gasket 580 is provided between evacuation port560 and evacuation plug 570. In some embodiments, gasket 580 aids insealing the evacuation port 560 with the evacuation plug 570 in theclosed configuration. Gasket 580, in some embodiments, surrounds atleast a portion of evacuation plug 570. In the embodiment of FIG. 6A,gasket 580 is shown surrounding portion 575 of evacuation plug 570 andis positioned between and configured to abut second portion 573 ofevacuation plug 570 and intermediate section 565 of evacuation port 560.In some embodiments, gasket 580 can be made from a metal or metal alloy,for example stainless steel, copper, aluminum, iron, titanium, tantalum,nickel, and alloys thereof. In some embodiments, gasket 580 is made froma ceramic, for example, aluminum oxide (Al₂O₃) and zirconium oxide(ZrO₂). In some embodiments, gasket 580 includes carbon or a carboncompound, for example, graphite.

In some embodiments, evacuation plug 570 is threadably coupled withevacuation port 560. According to some of these embodiments, at least aportion of inner surface 568 is provided with internal threads that areconfigured to engage with external threads provided on at least aportion of evacuation plug 570 such that, for example, evacuation plug570 may be screwed into evacuation port 560. In some embodiments, one ormore of portions 572, 573, 574, and 575 may be provided with externalthreads that engage with internal threads provided on inner surface 568of evacuation port 560. In some embodiments, the filling configurationincludes partially engaging the external threads of evacuation plug 570with the internal threads of evacuation port 560 (e.g., partiallyscrewing evacuation plug 570 into evacuation port 560) and the closedconfiguration includes fully engaging the external threads of evacuationplug 570 with the internal threads of evacuation port 560 (e.g., fullyscrewing evacuation plug 570 into evacuation port 560).

In some embodiments, evacuation port 560 and evacuation plug 570 may bepermanently secured together. In some embodiments, evacuation port 560and evacuation plug 570 may be mechanically secured together. In someembodiments, evacuation port 560 may be fused with evacuation plug 570.In some embodiments, evacuation port 560 and evacuation plug 570 may besoldered or brazed together. In some embodiments, evacuation port 560and evacuation plug 570 may be welded together along seam 566, forexample, by orbital welding. In such embodiments, the weld is placedbetween the evacuation port 560 and evacuation plug 570 away from thegasket 580 so not to disrupt the hermetic seal maintaining theatmosphere in the container 500. In other embodiments, an adhesive orcement may be introduced into seam 566 to seal evacuation port 560 andevacuation plug 550 together.

Referring to FIGS. 5A and 6A, container 500, in some embodiments,includes lifting member 530 which is configured to engage with a carrierfor lifting and/or transporting container 500. Lifting member 530,according to some embodiments, is securely attached to and extends fromexterior surface 526 of lid 520. In some embodiments, lifting member 530is positioned centrally on exterior surface 526 of lid 520. In someembodiments, lifting member 530 is integrally formed with lid 520. Inother embodiments, lifting member is formed separately from lid 520 andsecured thereto, for example, by welding, soldering, brazing, or thelike. In some embodiments, lifting member 530 is constructed from metalor metal alloy, and may be made from the same material as body 510and/or lid 520.

In the exemplary embodiment shown, lifting member 530 includes agenerally cylindrical projection 532 extending from lid 520substantially co-axial with central longitudinal axis 511. In someembodiments, lifting member 530 is radially symmetric about centrallongitudinal axis 511. In some embodiments, lifting member 530 ispositioned on lid 520 between filling port 540 and evacuation port 560.In some embodiments, lifting member 530 includes a groove 533 thatextends at least partially around the circumference of projection 532.In further embodiments, lifting member 530 includes a flange 534 thatpartially defines groove 533.

FIGS. 5B and 6B show another embodiment of a container, generallydesignated 600, for containment and storage of nuclear waste materialsor other desired contents in accordance with an exemplary embodiment ofthe present invention. Container 600, in some embodiments, isparticularly useful in hot isostatic pressing of waste materials. Insome embodiments, body 610 is constructed of material capable ofmaintaining a vacuum within body 600.

According to some embodiments, container 600 generally includes body610, lid 620, and filling port 640. In some embodiments, container 600also includes filling plug 650 configured to engage with filling port640.

Body 610 has a central longitudinal axis 611 and defines interior volume616 for containing nuclear waste materials or other materials accordingto certain embodiments of the invention. In some embodiments, a vacuumcan be applied to interior volume 616. In some embodiments, body 610 hasa cylindrical or a generally cylindrical configuration having closedbottom end 615. In some embodiments, body 610 is substantially radiallysymmetric about central longitudinal axis 611. In some embodiments, body610 may be configured to have the shape of any of the containersdescribed in U.S. Pat. No. 5,248,453, which is incorporated herein byreference in its entirety. In some embodiments, body 610 is configuredsimilarly to body 110 of container 100 shown in FIG. 1. Referring toFIG. 5B, in some embodiments body 610 has one or more sections 612having a first diameter alternating along central longitudinal axis 611with one or more sections 614 having a smaller second diameter. Body 610may have the same configuration and dimensions described herein for body510.

Body 610 may be constructed from any suitable material known in the artuseful in hot isostatic pressing of nuclear waste materials. In someembodiments, body 610 is constructed from a material that is resistantto corrosion. In some embodiments, body 610 is made from a metal ormetal alloy, for example, stainless steel, copper, aluminum, nickel,titanium, and alloys thereof.

In some embodiments, container 600 includes a lid 620 opposite closedbottom end 615, Lid 620, in some embodiments, is integrally formed withbody 610. In other embodiments, lid 620 is formed separately from body610 and secured thereto, for example, via welding, soldering, brazing,fusing or other known techniques in the art to form a hermetic sealcircumferentially around lid 620. In some embodiments, lid 620 ispermanently secured to body 610. Referring to FIG. 6B, lid 620 includesinterior surface 624 facing interior volume 616 and exterior surface 626opposite interior surface 624. In some embodiments, central longitudinalaxis 611 is substantially perpendicular to interior surface 624 andexterior surface 626. In some embodiments, central longitudinal axis 611extends through a center point of interior surface 624 and exteriorsurface 626. In some embodiments, container 600 further includes aflange 622 surrounding exterior surface 626.

In some embodiments, container 600 further includes a filling port 640having an outer surface, a stepwise inner surface 647 and a lower innersurface 648 defining a passageway in communication with interior volume616, and configured to couple with a filling nozzle. In someembodiments, the nuclear waste material to be contained by container 600is transferred into interior volume 616 through filling port 640 via thefilling nozzle. In some embodiments, filling port 640 is configured toat least partially receive the filling nozzle therein. In someembodiments, stepwise inner surface 647 and/or lower inner surface 648of filling port 640 is configured to form a tight seal with a fillingnozzle so as to prevent nuclear waste material from exiting interiorvolume 616 between stepwise inner surface 647 and lower inner surface648 of filling port 640 and the filling nozzle during filling ofcontainer 600.

Filling port 640 may extend from lid 620 as shown in the exemplaryembodiment of FIGS. 5B and 6B. In some embodiments, filling port 640 maybe integrally formed with lid 620. In other embodiments, filling port640 is formed separately from lid 620 and secured thereto, for example,by welding. In some embodiments, filling port 640 is constructed frommetal or metal alloy, and may be made from the same material as body 610and/or lid 620.

Referring particularly to FIG. 6B, filling port 640 has a generally stepwise tubular configuration with stepwise inner surface 647 and lowerinner surface 648 extending from first end 642 towards second end 643.According to some embodiments, filling port 640 extends from lid 620along an axis 641 substantially coaxial to central longitudinal axis611. In some embodiments, stepwise inner surface 647 is radiallydisposed about axis 641. In some embodiments, lower inner surface 648 isradially disposed about axis 641. In some embodiments, first end 642 offilling port 640 defines an opening in lid 620 and has an internaldiameter D_(g1). In some embodiments, second end 643 of filling port 640has an internal diameter D_(g2) which may be different than diameterD_(g1). In some embodiments, D_(g2) is larger than D_(g1).

In some embodiments, filling port 640 is provided with a flange 634 atleast partially defining a groove 633. In some embodiments, flange 634and groove 633 extend circumferentially around filling port 640. In someembodiments, flange 634 and groove 633 are radially symmetric about axis641. In some embodiments, flange 634 and/or groove 633 are configured toengage with a carrier for lifting or transporting container 600.

Container 600, in some embodiments, further includes a filling plug 650configured to couple with filling port 640. In some embodiments, fillingplug 650 is configured and dimensioned to be at least partially receivedin filling port 640 as generally shown in FIG. 6B. In some embodiments,filling plug 650 is radially disposed about axis 641 when coupled withfilling port 640. In some embodiments, filling plug 650 is configured toclose and seal filling port 640 to prevent material from exitinginterior volume 616 via filling port 640. In some embodiments, fillingplug 650 is configured for hermetically sealing filling port 640.

Filling plug 650, in some embodiments, is configured to abut stepwiseinner surface 647 when coupled to filling port 640. In some embodiments,filling plug 650 includes a first portion 673 having a diametersubstantially equal to D_(g2). In some embodiments, filling plug 650alternatively or additionally includes a second portion 675 having adiameter substantially equal to D_(g3). In some embodiments, fillingplug 650 alternatively or additionally includes a third portion 674having a diameter substantially equal to D_(g4). In some embodiments,first portion 673 is configured to abut surface 649 when filling plug650 is coupled with filling port 640.

In some embodiments, filling plug 650 when coupled with filling port 640creates a seam 646. In some embodiments, seam 646 is formed at aninterface between filling plug 650 and end surface 645 of second end 643of filling port 640. In some embodiments, seam 646 is located between anexternal surface of filling plug 650 and an external surface of fillingport 640. In some embodiments, the external surface of filling plug 650is substantially flush with the external surface of filling port 640proximate seam 646. Seam 646 extends circumferentially around a portionof filling plug 650 according to some embodiments.

Filling port 640 and filling plug 650 may be secured together accordingto some embodiments by any suitable method known in the art. In someembodiments, filling plug 650 is threadably coupled with filling port640. According to some of these embodiments, at least a portion of innersurface 648 is provided with internal threads that are configured toengage with external threads provided on at least a portion of fillingplug 650 such that, for example, filling plug 650 may be screwed intofilling port 640. In some embodiments, one or more of portions 652 and653 may be provided with external threads that engage with internalthreads provided on inner surface 648 of filling port 640. In otherembodiments, filling port 640 and filling plug may be coupled via aninterference or friction fit.

In some embodiments, a gasket 680 is provided between filling port 640and filling plug 650. In some embodiments, gasket 680 aids in sealingthe filling port 640 with the filling plug 650 in a closedconfiguration. Gasket 680, in some embodiments, surrounds at least aportion of filling plug 650. In the embodiment of FIG. 6B, gasket 680 isshown surrounding portion 675 of filling plug 650 and is positionedbetween and configured to abut portion 673 of filling plug 650 andfilling port 640. In some embodiments, gasket 680 can be made from ametal or metal alloy, for example stainless steel, copper, aluminum,iron, titanium, tantalum, nickel, and alloys thereof. In someembodiments, gasket 680 is made from a ceramic, for example, aluminumoxide (Al₂O₃) and zirconium oxide (ZrO₂). In some embodiments, gasket680 includes carbon or a carbon compound, for example, graphite.

In some embodiments, filling port 640 and filling plug 650 may bepermanently secured together after filling of container 600 with thenuclear waste material or other desired contents. In some embodiments,filling port 640 and filling plug 650 may be mechanically securedtogether. In some embodiments, filling port 640 may be fused withfilling plug 650. In some embodiments, filling port 640 and filling plug650 may be soldered or brazed together. In some embodiments, fillingport 640 and filling plug 650 are configured to provide a hermetic seal.In some embodiments, filling port 640 and filling plug 650 may be weldedtogether along seam 646, for example, by orbital welding. In suchembodiments, the weld is placed between the filling plug 650 and fillingport 640 away from the gasket 680 so as not to disrupt the hermetic sealmaintaining the atmosphere in the container 600. In other embodiments,an adhesive or cement may be introduced into seam 646 to seal fillingport 640 and filling plug 650 together.

According to some embodiments of the invention, filling plug 650 isprovided with a filter 690. In some embodiments, filter 690 is sized tospan the circular end section 670 of filling port 650. In someembodiments, the filter 690 is sealingly engaged to circular end section670 of filling plug 650. In some embodiments, the filter 690 is securedto circular end section 670 of filling plug 650, for example, viawelding, soldering, brazing, or the like. In some embodiments, filter690 is secured to filling plug 650 with a mechanical fastener 695, suchas a screw, nail, bolt, staple, or the like. In one embodiment, filter690 is a high efficiency particulate air (HEPA) filter. In someembodiments, filter 690 is a single layer of material. In someembodiments, filter 690 is multi-layer material. In some embodiments,filter 690 is made from sintered material. In some embodiments, filter690 is made from metal or metal alloy, for example, stainless steel,copper, aluminum, iron, titanium, tantalum, nickel, and alloys thereof.In some embodiments, filter 690 is made from a ceramic, for example,aluminum oxide (Al₂O₃), aluminosilicates (eg. Al₂SiO₅) and zirconiumoxide (ZrO₂). In some embodiments, filter 690 includes carbon or acarbon compound, for example, graphite. In some embodiments, thematerial of filter 690 is chosen so that upon heating the filterdensifies into a solid and non-porous material. In some embodiments, thematerial of filter 690 is chosen wherein at a first temperature filter690 is porous to air and/or gas but prevents passage of particles and ata second temperature filter 690 densifies into a non-porous material,wherein the second temperature is greater than the first temperature.

In some embodiments, filter 690 is configured to prevent passage ofparticles having a predetermined dimension through filling port 640while allowing passage of air or other gas when filling plug 560 iscoupled with filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 100 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 75 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 50 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 25 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 20 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 15 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 12 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 10 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 8 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 5 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 1 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 0.5 μm through filling port 640. In some embodiments, filter 690 isconfigured to prevent passage of particles having a dimension greaterthan 0.3 μm through filling port 640.

According to some embodiments of the invention, filling plug 650 isconfigured to be at least partially received within filling port 640 ina filling configuration such that air and/or other gas is allowed toexit from interior volume 616 of container 600 through filter 690 andbetween stepwise inner surface 647 of filling port 640 and filling plug650. In some embodiments, filling plug 650 and filling port 640 arecoupled in the filling configuration such that a gap (not shown) ofsufficient dimension to provide a pathway for air and/or other gas toevacuated from interior volume 616. In some embodiments, the gap extendscircumferentially around at least a portion of filling plug 650. In someembodiments, air and/or other gas is allowed to pass through the gap andthrough seam 646 in the filling configuration.

In operation, the interior volume of a container 216 is filled withmaterial by coupling a filling port 540 to a filling nozzle 260 whereincontainer 216 is place under a negative pressure prior to filling orcontainer 216 is simultaneously evacuated during the filling processaccording to some embodiments. In some embodiments, the filling port 540is configured to tightly fit around the filling nozzle 260 to preventmaterial from exiting container 216 between the filling port 540 and thefilling nozzle 260. In some embodiments, the filling of container 216continues until the desired amount of material has been added tocontainer 216. In some embodiments, a predetermined volume of materialis added to container 216. In some embodiments, a predetermined weightof material is added to container 216.

With reference to FIG. 6A, material to be stored (e.g., nuclear waste orcalcined material) is added to interior volume 516 of container 500 viaa filling nozzle 260 coupled to filling port 540 according to someembodiments. In some embodiments, the filling port 540 is configured totightly fit around filling nozzle 260 to prevent material from exitingcontainer 500 between the filling port 540 and filling nozzle 260. Insome embodiments, as container 516 is being filled, air and/or other gascontained in interior volume 516 is evacuated from container 500 viaevacuation port 560 provided with filter 590. In some embodiments,filter 590 prevents all or at least most non-gaseous materials fromexiting container 500 through evacuation port 560 while the air and/orother gas is being evacuated from interior volume 516. In someembodiments, filter 590 is configured to prevent particles having adiameter of at least 10 μm from exiting interior volume 516 throughevacuation port 560 during filling of waste material and air/gasevacuation. Evacuation of the air and/or other gas, in some embodiments,can be facilitated by coupling evacuation port 560 with an evacuationnozzle 300. Evacuation nozzle 300 may be coupled with an evacuation lineor system (e.g., a vacuum source). In some embodiments, the evacuationline is operated at vacuum levels of about 25 to about 500 millitorr.

After filling container 500 with the desired amount of material, fillingnozzle 260 is replaced with filling plug 550 to close and seal fillingport 540. In some embodiments, filling port 540 is hermitically sealedwith filling plug 550. In some embodiments, filling plug 550 is weldedto filling port 540. In some embodiments, an orbital welder 242 is usedto weld filling plug 550 to filling port 540.

In some embodiments, evacuation port 560 may be provided with evacuationplug 570. As previously described, evacuation plug 570 may be threadablycoupled with evacuation port 560 in a first open configuration to allowair and/or other gas to pass through filter 590 and between evacuationplug 570 and evacuation port 560 and in a second closed configuration tohermitically seal and close evacuation port 560. In some embodiments,after filling is complete, evacuation port 560 is closed by evacuationplug 570. In some embodiments, evacuation port 560 is closed whileevacuation nozzle 300 is coupled to evacuation port 560.

With reference to FIG. 6B, container 600 is evacuated by couplingfilling port 640 with an evacuation line or system (e.g., a vacuumsource). Material is then added to interior volume 616 of container 600via a filling nozzle 260 coupled to filling port 640. In someembodiments, the filling port 640 is configured to tightly fit aroundfilling nozzle 260 to prevent material from exiting container 600between the filling port 640 and filling nozzle 260. In someembodiments, container 600 is evacuated to a pressure of about 750millitorr to about 1000 millitorr prior to filling.

After filling container 600 with the desired amount of material, fillingnozzle 260 is replaced with filling plug 650 to close and seal fillingport 640 according to some embodiments. In some embodiments, container600 is returned to the atmospheric pressure (e.g. the pressure of firstcell 217) after filling.

FIGS. 8-11 illustrate an exemplary filling system 299 for transferringhazardous waste material into a container 216 in accordance with variousembodiments of the present invention. Filling system 299, in accordancewith some embodiments of the present invention, is designed to preventcontamination of equipment and container exterior and elimination ofsecondary waste. The design features include, but are not limited to:container structure to allow container filling under vacuum; weightverification system and/or volume verification system; and fillingnozzle structure. As illustrated, in FIGS. 8-10, in some embodiments,system 299 for transferring hazardous waste material into a sealablecontainer 216 includes a filling nozzle 260, at least one hopper 214, apneumatic cylinder 285, a seal 284, a vibrator 281, a lift mechanism282, a damper 283, a first scale 277, a second scale 278 and a processor280.

The system of FIGS. 8-11 may be used with a container having a singleport, such as container 600, or a container having two ports, such ascontainer 500, as described above herein. FIG. 8 illustrates a fillingnozzle 260 relative to an exemplary container 216 having a single port291. FIG. 9 illustrates a filling nozzle 260 relative to an exemplarycontainer 216 having two ports, a filling port 292 and an evacuationport 293. In some embodiments, filling port 292 and evacuation port 293may have the configuration of filling port 540 and evacuation port 560of container 500 illustrated in FIGS. 5A and 6A. In one embodiment, theevacuation port 293 includes a filter 350. In some embodiments, filter350 prevents the escape of hazardous waste particles from the container.Exemplary filter materials are discussed above herein. In someembodiments, filter 350 has the configuration of filter 590 as describedabove herein. In some embodiments, the transfer of hazardous waste isperformed to prevent overpressure of container 216. In some embodiments,container 216 is at least initially under negative pressure beforetransfer of hazardous waste begins. In other embodiments, container 216is under negative pressure simultaneously with the transfer of hazardouswaste. In yet other embodiments, container 216 is initially undernegative pressure before the filling process begins and isintermittently placed under negative pressure with the transfer ofhazardous waste. In another embodiment, filling port 292 of container216 is configured to be sealed closed after decoupling valve body 261from filling port 292.

In some embodiments, container 216 is filled at about 25° C. to about35° C. In other embodiments, container 216 is filled at a temperature upto 100° C.

Referring to FIGS. 2 and 11, in one embodiment, additive from theadditive feed hopper 210 is added to the feed blender 212. In one suchembodiment, the amount of additive is metered using an additive feedscrew (not shown). Feed blender 212 is actuated to mix the calcinedmaterial with the additive. In one embodiment, feed blender 212 is amechanical paddle-type mixer with the motor drives external to the cell.Referring to FIG. 8, in one embodiment a rotary airlock or ball valve298, located between the feed blender 212 and hopper 214, transfers themixed calcined material to feed hopper 214. In another embodiment, arotary air lock or ball valve 298 is positioned between feed hopper 214and container 216 to control transfer of material therebetween

Referring to FIG. 7, in some embodiments, a fixed volume of the mixedcalcined material is transferred from feed hopper 214 to container 216which is located in first cell 217. In one embodiment, container 216 hastwo ports, a fill and an evacuation port, as described herein. Inanother embodiment, container 216 has a single port as described herein.Fill port 540, 640, attached to the top of container 216, is mated to afill nozzle, discussed below herein, that is designed to eliminatespilling any of the hazardous material on the exterior of container 216.In one embodiment, fill nozzle 260 and fill port 540, 640 are configuredto prevent contamination with waste material of the seal between afilling plug 550 and the interior of fill port 540, 640.

In one embodiment, the amount of hazardous material transferred to acontainer is carefully controlled to ensure that container 216 issubstantially full without overfilling container 216. In someembodiments, a weight verification system connected to hopper 214 andcontainer 216 ensures that the proper amount of material is transferred.In some embodiments, equal volumes between hopper and container incombination with weight verification system connected to hopper 214 andcontainer 216 ensure that the proper amount of material is transferred.In some embodiments, the weight verification system includes a processor280 and a plurality of weigh scales 277. In some embodiments, a firstscale 277 is coupled to the hopper 214 and configured to determine aninitial hopper weight; a second scale 278 is coupled to the container216 and configured to determine a container fill weight; and a processor280 is coupled to the first scale 277 and the second scale 278 andconfigured to compare the initial hopper weight to the container fillweight. In some embodiments, initial hopper weight is the weight betweenflange 294 and flange 295 including hopper 214. In some embodiments,initial hopper weight means the weight of hazardous material within thehopper prior to filling container 216. In some embodiments, containerfill weight means the weight of hazardous material in container 216during the filling process and/or at the end of the filling process. Inone embodiment, hopper 214 includes a volume substantially equal to avolume of container 216.

In some embodiments, one or more vibrators 281 are provided to one ormore components of filling system 299 to help ensure that all of thematerial is transferred from hopper 214 to container 216. In someembodiments, one or more vibrators 281 are configured to apply avibrating force to one or more components of system 299 in order toassist in transferring the material to container 216. In someembodiments, vibrators 281 are configured to provide at least a force ina vertical direction. In some embodiments, vibrators 281 are configuredto provide at least a force in a lateral direction. In one embodiment,at least one vibrator 281 is coupled to hopper 214, for example, toshake material from hopper 214 to container 216. In one embodiment, atleast one vibrator 281 is coupled to a bottom of container 216. In onesuch embodiment, vibrator 281 coupled to bottom of container 216 isconfigured to provide vibration to container 216 in at least a verticaldirection. In one embodiment, at least one vibrator 281 is coupled to asidewall of the container 216. In one such embodiment, vibrator 281coupled to the sidewall of container 216 is configured to providevibration to container 216 in at least a lateral direction. The one ormore vibrators 281, in some embodiments, are coupled a processorconfigured to control activation and/or operation (e.g., frequency) ofvibrators 281. In some embodiments, processor 280 is coupled to the oneor more vibrators 281. In some embodiments, one or more vibrators 281are activated if container 216 is determined to be under-filled, forexample, where the material to be transferred has been held up insidethe system. In one embodiment, one or more vibrators 281 are activatedif the container fill weight is less than the initial hopper weight.

Referring to FIGS. 8 and 10, in one embodiment, filling nozzle 260includes a valve body 261, a valve head 265 and a valve stem 267. Valvebody 261 includes a distal end 262 and an outer surface 263, valve body261 including a valve seat 264 proximate distal end 262, outer surface263 proximate distal end 262 configured to sealingly and removeablycouple valve body 261 to a filling port 272 of a container 216. Incertain embodiments, valve body 261 includes a first branch section 270configured to couple to hopper 214. In one embodiment, a second branchsection 269 includes the distal end 262 of the filling nozzle 260 andhas a proximal end 288. In one embodiment, the proximal end 288 iscoupled to a drive mechanism 289 configured to move the valve stem 267.In one embodiment, valve head 265 includes a valve face 266 configuredto form a seal with the valve seat 264 in a closed configuration. In oneembodiment, valve head 265 is configured to allow valve body 261 andcontainer 216 to be fluidly coupled with one another in an openconfiguration. In certain embodiments, valve head 265 extends distallyfrom valve body 261 and into container 216 in the open configuration.Valve stem 267 extends co-axially with axis 276 from valve head 265through at least a portion of valve body 261. In a further embodiment,valve stem 267 extends through proximal end 288 of second branch section269, proximal end 288 including a seal 284 coupled to a portion of valvestem 267.

In some embodiments, filling nozzle 260 is sealed with filling port 272of container 216 to prevent spilling of the hazardous waste materialfrom container 216. In one embodiment, filling nozzle 260 extends intofilling port 272 to prevent waste material from interfering with theseal between a filling plug (e.g. filling plug 650) and filling port 272after removing filling nozzle 260. In some embodiments, outer surface263 of distal end 262 includes at least one seal 273 to form a seal withfilling port 272. In another embodiment, at least one seal 273 includesat least one o-ring. In one embodiment, at least one seal 273 includestwo o-ring seals. In some embodiments, outer surface 263 includes asecond seal 275 to form a seal with filling port 272. In someembodiments, filling port 272 has the configuration of filling port 640of container 600, and at least one of seals 273 and 275 engages withlower inner surface 648 to form a seal therewith. In some embodiments,at least one of seals 273 and 275 engages with lower inner surface 648at a position between first end 642 and where filter 690 engages fillingport 640 as shown in FIG. 6B. In some embodiments, at least one of seals273 and 275 engages with stepwise inner surface 647 at a positionbetween first end 642 and gasket 680.

In one embodiment, filling nozzle 260 further includes a sensor 274disposed in valve head 265. In one embodiment, sensor 274 is configuredto determine a level of hazardous material in container 216. In oneembodiment, sensor 274 extends distally from valve body 261. In anotherembodiment, sensor 274 is coupled to a wire 268 that extends throughvalve stem 267. In one embodiment, sensor 274 is coupled to a wire 268that extends through valve stem 267. Suitable sensors may includecontact type sensors including displacement transducer or forcetransducer. In such embodiments, a displacement transducer sensesfilling powder height. In such embodiments, a force transducer includesa stain gauge on thin membrane that is deflected by the filling powderfront. Suitable sensors may also include non contact type sensorsincluding sonar, ultrasonic, and microwave. In one embodiment, a drivemechanism operates valve stem 267. In one embodiment, drive mechanism289 includes a pneumatic cylinder 285. In some embodiments, a liftmechanism 282 is configured to lift container 216 toward filling nozzle262. In one embodiment, lift mechanism 282 includes at least one damper283.

In one embodiment, the system for transferring hazardous waste materialinto the sealable container further comprises a vacuum nozzle 271configured to be in fluid communication with container 216. In oneembodiment, vacuum nozzle 271 extends through distal end 288 of valvebody 261. In another embodiment, vacuum nozzle 271 includes a filter 279proximate the distal end 262 of valve body 261. In certain embodiments,the system in accordance with the present invention further comprises avacuum nozzle 271 sealingly and removeably couplable with the exhaustport 292, vacuum nozzle 271 being in sealed fluid communication with thevalve body 261 in a filling configuration.

In one embodiment, first cell 217 does not exchange air with subsequentcells while at least container 216 is being filled by the filling system299. Referring to FIG. 7, in one embodiment, first cell 217 includes anoff-gas sub-system 206 coupled to filling system 299 wherein off-gassub-system 206 has a vacuum nozzle configured to couple to container216.

Referring to FIG. 12, in a further embodiment, first cell 217 is coupledto the second, subsequent cell 218 with one or more sealable doors 240.In one embodiment, the second, subsequent cell 218 is a bake-out andvacuum sealing cell. In one embodiment, first cell 217 is coupled tosecond cell 218 via an air interlock 241. In one embodiment, airinterlock 241 is configured to allow container 216 to be transferredfrom first cell 217 to second cell 218.

II. Second Cell

Exemplary embodiments of second cell 218 and certain components thereofare illustrated in FIGS. 2, 3, 4, 12, 13, 14 and 16. In one embodiment,second cell 218 is a bake-out and vacuum sealing cell which allows forheating and evacuating container 216 followed by sealing of container216. In one embodiment, first cell 217 is held at a first pressure P1and second cell 218 is held at a second pressure P1, where the firstpressure P1 is less than the second pressure P2. First cell 217 andsecond cell 218 are interconnected via the sealable door 240 accordingto some embodiments.

In one embodiment, second cell 218 includes a baking and sealing station243. In certain embodiments, second cell 218 further includes a weldingstation. Referring to FIG. 2, in one embodiment, second cell 218includes a bake-out furnace 290, an off-gas system 206 having a vacuumnozzle configured to couple to the container 216. In some embodiments,as shown in FIG. 16, second cell 218 further includes an orbital welder242 configured to apply a weld to container 216.

In one embodiment, referring to FIGS. 3 and 12, second cell 218 includesan interlock 241, interlock 241 coupling first cell 217 to second cell218 and configured to allow container 216 to be transferred from firstcell 217 to second cell 218 while maintaining at least one seal betweenthe first cell 217 and second cell 218. In one embodiment, interlock 241includes decontamination equipment. In another embodiment, first cell217 and interlock 241 may be communicatively interconnected via sealabledoor 240, allowing container 216 to be transferred from first cell 217to interlock 241. In a further embodiment, first cell 217 and secondcell 218 include a roller conveyer 246 configured to allow containers216 to be loaded thereon and transported within and/or between eachcell.

Referring again to FIG. 2, in some embodiments, second cell 218 includesa furnace 290 configured for heating container 216 in a bake-outprocess. In some embodiments, the bake-out process includes heatingcontainer 216 in furnace 290 to remove excess water and/or othermaterials, for example, at a temperature of about 400° C. to about 500°C. for several hours. In some embodiments, a vacuum is established oncontainer 216 and any off-gas is removed from container 216 during thebake-out process. The off-gas may include air from container 216 and/orother gas released from the waste material during the bake-out process.In some embodiments, the off-gas removed from container 216 is routedthrough line 206, which may lead out of second cell 218 and may beconnected to a further ventilation system. Line 206, in someembodiments, includes one or more filters 204 to capture particulatesentrained in the off-gas. Filters 204 may include HEPA filters accordingto some embodiments. In further embodiments, line 206 includes one ormore traps 219 for removing materials such as mercury that may not bedesirable to vent. For example, trap 219 in one embodiment may include asulfur impregnated carbon bed trap configured to trap mercury containedin the off-gas from container 216. In further embodiments, a vacuum isestablished in container 216 during the bake-out process and container216 may then be sealed to maintain the vacuum.

Evacuation of the air and/or other gas from container 216, in someembodiments, is achieved by coupling container 216 with an evacuationsystem. FIG. 13 illustrates an exemplary evacuation system that can beused in accordance with embodiments of the invention shown coupled tofilling plug 640 of container 600 as described above herein. It shouldbe understood that the evacuation system depicted in FIG. 13, in otherembodiments, may be coupled to containers having other configurations.For example, the evacuation system may be coupled to evacuation port 560of container 500 shown in FIGS. 5A and 6A.

Referring again to FIG. 13, the evacuation system shown includes anevacuation nozzle 300, which may be coupled with an evacuation line orother a vacuum source. In some embodiments, evacuation nozzle 300 isfurther coupled to a vacuum transducer 301 configured to measure thevacuum level in container 600. In some embodiments, evacuation nozzle300 is coupled to a valve 302. In some embodiments, valve 302 isconfigured to isolate container 600 from the vacuum source, which inturn allows for the detection of leaks in container 600 or detection ofgas being evolved from interior volume 616. The detection can beaccomplished, for example, by measuring pressure change (e.g. usingvacuum transducer 301) as a function of time. An increase in pressure(or loss of vacuum) in container 600 over time may indicate, forexample, a possible leak or gas generation from interior volume 616. Insome embodiments, evacuation nozzle 300 further includes a filterconfigured to prevent passage of particulate matter there through.

As illustrated, evacuation nozzle 300 in some embodiments is coupled tofilling plug 650 and/or filling port 640 of container 600. In someembodiments, evacuation nozzle 300 fits around filling plug 650 andfilling port 640. In some embodiments, evacuation nozzle 300 isconfigured to at least partially surround filling plug 650 and fillingport 640 when filling plug 650 is coupled with filling port 640. In someembodiments, evacuation nozzle 300 forms a circumferential seal withfilling port 640 when coupled thereto. In some embodiments, evacuationnozzle 300 seats against flange 634. In some embodiments, evacuationnozzle 300 includes a gasket that engages with an external surface offilling port 640 to form a hermitic seal therewith when evacuationnozzle is coupled with filling port 640.

In some embodiments, filling plug 650 may be threadably coupled withfilling port 640 in a first open configuration to allow air and/or othergas to pass through filter 690 and between filling plug 650 and fillingport 640 and in a second closed configuration to hermitically seal andclose filling port 640. In some embodiments, air and/or other gas isallowed to pass between filling plug 650 and filling port 640 andthrough seam 646. In some embodiments, evacuation nozzle 300 isconfigured to withdraw air and/or other gas from interior volume 616 ofcontainer 600 when filling plug 650 and filling port 640 are in thefirst open configuration. In some embodiments, after air and/or othergas is withdrawn from interior volume 616, a vacuum is created withininterior volume 616 and filling plug 650 is used to hermetically sealfilling port 640 in the closed configuration so as to maintain thevacuum.

In some embodiments evacuation nozzle 300 is fitted with a torque 304having a stem 303. In some embodiments, stem 303 has a proximal end anda distal end, said distal end being configure to mate with a recess infilling plug 650, and the proximal end being coupled to a handle. Insome embodiments, the handle of torque 304 is manipulated to threadablytighten filling plug 650 to filling port 640, thereby forming a tightseal between the filing plug 650 and filling port 640. In someembodiments, torque 304 is manipulated with a drive shaft.

In some embodiments, when the bake-out process is completed, the vacuumis maintained on container 600 through the evacuation system. In someembodiments, when the vacuum reaches a set point, the vacuum isverified, for example using vacuum transducer 301 as described aboveherein, and filling port 640 is closed (e.g., hermetically scaled) byfilling plug 650 and the evacuation system is removed. In someembodiments, filling plug 650 is then welded to filling port 640. Insome embodiments, filling plug 650 is welded to filling port 640 by anorbital welder 242, which may be positioned in a welding station insecond cell 218. An embodiment of an orbital welding station isillustrated in FIG. 14, which shows orbital welder 242 configured toweld filling plug 650 onto filling port 640 of container 600 at seam646. In some embodiments, orbital welder 242 is remotely operated. Insome embodiments, welds applied by orbital welder 242 are visuallyinspected.

While the foregoing description of the evacuation system and orbitalwelder 242 makes reference to container 600, it should be understoodthat these elements may be similarly used on other configurations forcontainer 216. For example, in other embodiments, these elements may besimilarly used to evacuate, seal, and weld container 500 at evacuationport 560. In these embodiments, where container 500 also includes aseparate filling port 540, filling port 540 may be similarly closed(e.g., by filling plug 550) and welded sealed by orbital welder 242prior to the bake-out process.

With reference again to FIG. 2, following the bake-out process,container 216, in some embodiments, is placed in containment 231 afterbeing removed from furnace 290. In some embodiments, containment 231provides for further contamination control in case of leakage or ruptureof container 216. In some embodiments, containment 231 may be pre-stagedon roller conveyor 246 for subsequent transport to third cell 232.

III. Third Cell

Exemplary embodiments of third cell 232 are illustrated in FIGS. 3, 4and 15. In one embodiment, third cell 232 is a HIP process cell whichallows for hot isostatic pressing of container 216. In one embodiment,third cell 232 includes a hot isostatic pressing station. In oneembodiment, first cell 217 is held at a first pressure P1, second cell218 is held at a second pressure P2 and third cell 232 is held at athird pressure P3. In one embodiment, first pressure P1 is less thansecond pressure P2 which is less than third pressure P3.

Referring to FIGS. 3, 4 and 16, in one embodiment, modular system 400 inaccordance with the present invention includes third cell 232, whereinthird cell 232 is isolated from first cell 217 and second cell 218, andwherein second cell 218 and third cell 232 are configured to allowcontainer 216 to be transferred from second cell 218 to third cell 232.In some embodiments, container 216 is transferred from second cell 218to third cell 232 in containment 231. In some embodiments, container 216is subjected to hot isostatic pressing in third cell 232. In someembodiments, container 216 is subjected to hot isostatic pressing whilein containment 231. In some embodiments, third cell 232 includes a hotisostatic pressing station 249. In one embodiment, hot isostaticpressing station 249 includes a HIP support frame 245, a hot isostaticpressing vessel 251 secured to support frame 245, and a pedestal mountedpick and place machine (robotic arm) 252 secured to the HIP supportframe 245, robotic arm 252 configured to manipulate within hot isostaticpressing station 249. In one embodiment, robotic arm 252 is configuredto lift and transfer container 216 from roller conveyer 246 intoisostatic process vessel 251.

In a further embodiment, third cell 232 includes a sealable door 240. Inone embodiment, sealable door 240 couples third 232 and second cell 218and is configured to allow container 216 to be transferred from secondcell 218 to third cell 232. In a further embodiment, second cell 218 andthird cell 232 each include a roller conveyer 246 configured to allowcontainer 216 to be loaded thereon and transported within and/or betweensecond 218 and third cell 232.

Hot isostatic pressing, according to some embodiments, includespositioning containment 231 holding container 216 in a hot isostaticpressing vessel 251. In some embodiments, container 231 is positioned byrobotic arms 252. In some embodiments, the hot isostatic pressing vessel251 is provided with an argon atmosphere (e.g., from argon source 236via argon line 202) which can be heated and pressurized. In someembodiments, for example, the hot isostatic pressing process isperformed by heating containment 231 holding container 216 to about1000° C. to about 1250° C. in the hot isostatic pressing vessel 251 forabout 2 hours to about 6 hours. In some embodiments, the pressure insidethe hot isostatic pressing vessel 251 is controlled to be about 4300 psito about 15000 psi during the hot isostatic pressing process. In someembodiments, compressors (e.g., 234) protected by in-line filtration areused to control the argon atmosphere of the hot isostatic pressingvessel 251. In some embodiments, the argon used during the hot isostaticpressing process is filtered and stored in a manner that conserves bothargon and pressure. Referring to FIG. 2, in some embodiments, the argonis recycled to argon source 236 via pump 238. The recycled argon, insome embodiments, passes through filter 233.

With reference to container embodiments illustrated in FIGS. 5A, 5B, 6Aand 6B, the material of filter 590 and/or filter 690 is chosen so thatupon heating during hot isostatic pressing the filter densifies into asolid and non-porous material forming a weld with container, containerevacuation port and/or container filling port. In some embodiments, thematerial of filter 590 and/or 690 is chosen wherein at a fillingtemperature filter 590 and/or 690 is porous to air and/or gas butdensifies into a non-porous material during hot isostatic pressing.

In some embodiments, after hot isostatic pressing is complete,containment 231 and container 216 is allowed to cool within the hotisostatic pressing vessel 251 to a temperature sufficient for removal(e.g., about 600 EC). In some embodiments, hot isostatic isostaticpressing vessel 251 includes a cooling jacket having cooling fluid(e.g., water) flowing therethrough. In some embodiments, the coolingjacket is supplied with cooling water at a rate of about 80 gpm to about100 gpm.

In some embodiments, containment 231 holding container 216 is removedfrom hot isostatic pressing vessel 251 and transferred to a coolingcabinet for cooling. In some embodiments, the cooling cabinet issupplied with a cooling fluid (e.g., water). In some embodiments, thecooling cabinet is supplied with cooling water at a rate of about 10gpm. In some embodiments, containment 231 and container 216 are allowedto cool in the cooling cabinet for about 12 hours. Following cooling inthe cooling cabinet, containment 231 holding container 216 is placed ona roller conveyor 246 for transport to fourth cell 230.

IV. Fourth Cell

Exemplary embodiments of fourth cell 230 are illustrated in FIGS. 3, 4and 17. In one embodiment, fourth cell 230 is a cooling cell whichallows for further cooling of container 216 after the hot isostaticpressing (HIP) process. In some embodiments, container 216 is packagedin fourth cell 230 for subsequent storage.

In a further embodiment, referring to FIGS. 3, 4 and 17, modular system400 in accordance with the present invention includes fourth cell 230,which may be a cooling cell. In one embodiment, fourth cell 230 isisolated from first 217, second cell 218 and third cell 220. In oneembodiment, third 232 and fourth cell 230 are configured to allowcontainer 216 to be transferred from third cell 232 to fourth cell 230.In one embodiment, first cell 217 is held at a first pressure P1,bake-out and second cell 218 is held at a second pressure P2, third cell232 is held at a third pressure P3 and fourth cell 230 is held at afourth pressure P4. In one embodiment, first pressure P1 is less thansecond pressure P2 which is less than third pressure P3 which is lessthan fourth pressure P4.

In a further embodiment, fourth cell 230 includes a moveable shieldedisolation door 240. In one embodiment, sealable door 240 is coupled tofourth cell 230 and third cell 232 and is configured to allow container216 to be transferred from third cell 232 to fourth cell 230. In afurther embodiment, each of third cell 232 and fourth cell 230 includesa roller conveyer 246 configured to allow container 216 to be loadedthereon and transported within and/or between third cell 232 and fourthcell 230. In yet another embodiment, fourth cell 230 includes an orbitalwelder 255.

In some embodiments, after transport to fourth cell 230, containment 231is opened and container 216 checked for evidence of container failure(e.g., deformation, expansion, breakage, etc.). In the event of failureof container 216, according to some embodiments, container 216 andcontainment 231 are moved to a decontamination chamber within fourthcell 230, decontaminated and returned to second cell 218 for possiblerecovery. If there is no evidence of failure of container 216, container216 is removed from containment 231 and transferred to a cooling andpacking station 250 in fourth cell 230 according to some embodiments. Ina further embodiment, cooling and packing station 250 includes a set ofat least one or more cooling stations. In one embodiment, at least oneor more cooling stations 253 configured to receive and hold processedcontainer 216 for final cooling. In some embodiments, container 216 ispassively cooled in cooling station 253. In some embodiments, container216 is actively cooled in cooling station 253.

In some embodiments, after final cooling, container 216 is packaged infourth cell 230 for transport and storage. In some embodiments, one ormore cooled containers 216 are placed in a canister. In someembodiments, the canister containing one or more containers 216 is thenwelded shut, for example, using an orbital welder 255. In someembodiments, the canister can then be transported for storage.

Referring to FIG. 2, any one of the cells of the modular system 400 mayinclude any suitable number of vacuum lines, including no vacuum line atall. As illustrated in FIG. 2, first cell 217, second cell 218, thirdcell 232 and fourth cell 230 may each include a set of one or morevacuum lines. Moreover, as illustrated in FIGS. 2, 3, 4, 5 and 10, firstcell 217, second cell 218, third cell 232 and fourth cell 230 may eachbe equipped with a set of at least one or more remotely operatedoverhead bridge cranes 239. In one embodiment, in addition to theirmaterial handling roles, each of these remotely operated overhead bridgecranes 239 are designed to be available for use in accomplishing eitherremote or manned maintenance of the equipment within the various cells.In another embodiment, each of the in-cell cranes may be configured tobe capable of being remotely removed from the cell via a larger craneprovided for maintenance purposes.

In some embodiments, secondary waste produced by modular system 400 ofthe present invention may be collected and transferred to containers 216for processing in accordance with steps of process flow 200. In someembodiments, for example, secondary waste is added to feed blender 212,mixed with calcined materials and/or additives, and transferred to acontainer 216 via a filling nozzle for subsequent hot isostaticpressing. Secondary waste, as used herein according to certainembodiments, refers to hazardous waste materials which are removed fromcontainer 216 and/or materials which are contaminated with hazardouswaste materials during steps of the present invention. In someembodiments, the secondary waste is converted to a form suitable fortransferring via the filling nozzle before introducing the secondarywaste into a container 216.

In some embodiments, secondary waste includes materials filtered ortrapped from the off gases evacuated from container 216. In one suchembodiment, secondary waste includes mercury captured from off gasevacuated from a container 216 during processing, for example, by one ormore traps 219 as described above herein. The mercury may be transformedinto an amalgam by mixing the mercury with one or more other metals andtransferred to another container 216 for further processing according toone example of this embodiment.

In some embodiments, secondary waste further includes system componentswhich may have been contaminated by or in direct contact with hazardouswaste material. The contaminated components may be combusted, crushed,pulverized, and/or treated in another manner prior to feeding to acontainer 216. In one such example, secondary waste includes a used cellor exhaust line filter (e.g., filter 204), which may contain hazardouswaste materials. In some embodiments, the used filter may be combustedand the resulting ashes are fed to a container 216 for furtherprocessing.

In some embodiments, at least 50% by weight of the secondary wasteproduced by modular system 400 is collected for processing. In someembodiments, at least 60% by weight of the secondary waste produced bymodular system 400 is collected for processing. In some embodiments, atleast 70% by weight of the secondary waste produced by modular system400 is collected for processing. In some embodiments, at least 80% byweight of the secondary waste produced by modular system 400 iscollected for processing. In some embodiments, at least 90% by weight ofthe secondary waste produced by modular system 400 is collected forprocessing. In some embodiments, at least 95% by weight of the secondarywaste produced by modular system 400 is collected for processing. Insome embodiments, at least 99% by weight of the secondary waste producedby modular system 400 is collected for processing.

Method of Processing Hazardous Waste Using a Modular System

In some embodiments, the systems, method and components described hereinprovide for a method of storing hazardous waste material comprising aplurality of steps and performed in a modular system. In someembodiments, one or more of the steps described herein can be performedin an automated manner. In a first cell, hazardous waste material isadded to a container via a filling nozzle coupled to a filling port ofthe container. Various embodiments of such filling nozzle are describedherein. The container is configured to sealingly contain the hazardouswaste material. In one embodiment, the container further includes anevacuation port. In one embodiment, the container is evacuated prior toadding the hazardous waste material by connecting a filling nozzlehaving a connector coupled to a vacuum system to thereby place thecontainer under a negative pressure. In another embodiment, thecontainer is evacuated during adding of the hazardous waste material viaan evacuation nozzle coupled to an evacuation port of the container tothereby maintain the container under a negative pressure during theadding step. In some embodiments, the amount of hazardous waste materialadded to the container is verified by measuring the weight of thecontainer after filling. Various embodiments of weight verificationsystems are described herein. In some embodiments, the amount ofhazardous waste material added to the container is verified by comparingthe weight (or change in weight) of the container after filling to theweight of hazardous waste material prior to filling. In one embodiment,a filling plug is inserted into the filling port to form a pluggedcontainer after the hazardous waste material is added to the containerto close the filling port. In another embodiment, a filling plug isinserted into the filling port and an evacuation plug is inserted intothe evacuation port prior to sealing the filling port to form a pluggedcontainer.

The plugged container is then transferred from the first cell to thesecond cell via the moveable shielded isolation door. In one embodiment,the plugged cell is transferred from the first cell to the second cellvia the moveable shielded isolation door and then into an interlock areacontaining contamination equipment.

In the second cell, the plugged container is connected to an evacuationnozzle coupled to an evacuation system and the container is heated. Insome embodiments, the container is heated in a bake-out furnace toremove excess water and/or other materials. In some embodiments, off-gasincluding air and/or other gas is removed from container during heating,for example, through the use of the evacuation nozzle. In oneembodiment, the evacuation nozzle is coupled to the evacuation port ofthe container. In such an embodiment, the evacuation plug is closedwhile the evacuation nozzle is couple to the evacuation nozzle. In onesuch embodiment, the evacuation port includes an evacuation plug whichis threadably coupled to the evacuation port. The evacuation plug allowsair and/or gas to pass through a filter, located in the evacuation port,and between the evacuation plug and the evacuation port in a heatingconfiguration. Prior to heating the container, the evacuation port is atleast partially opened. The container is then heated. Following theheating step, the evacuation port is placed in a closed configurationand is sealed in one embodiment. In one such embodiment, the vacuum onthe container is maintained for a period of time following the heatingstep prior to sealing. Optionally, the maintenance of the vacuum in thecontainer is verified. In one such embodiment, the sealing step isperformed by welding an evacuation plug to the evacuation port to sealthe evacuation port. In such an embodiment, the welding is performedusing an orbital welder.

In another embodiment, the evacuation nozzle is coupled to the fillingport of the container. In such an embodiment, the filling plug is closedwhile the evacuation nozzle is couple to the evacuation nozzle. In onesuch embodiment, the filling port includes a filling plug which isthreadably coupled to the filling port. The filling plug allows airand/or gas to pass through a filter, located in the filling plug, andbetween the filling plug and the filling port in a heatingconfiguration. Prior to heating the container, the filling port is atleast partially opened. The evacuated container is then heated.Following the heating step, the filling port is closed in a closedconfiguration and is sealed. In one such embodiment, the vacuum on thecontainer is maintained for a period of time following the heating stepprior to sealing. Optionally, the maintenance of the vacuum in thecontainer is verified. In one such embodiment, the sealing step isperformed by welding the filling plug to the filling port to seal thefilling port. In such an embodiment, the welding is performed using anorbital welder.

Following the sealing step, the sealed container is transferred from thesecond cell to the third cell via a second moveable shielded isolationdoor. In some embodiments, the sealed container is transferred from thesecond cell to the third cell inside a containment. The sealed containeris then subjected to hot isostatic pressing. In some embodiments, thesealed container is subjected to hot isostatic pressing while inside thecontainment. In some embodiments, hot isostatic pressing includessubjecting the sealed container to a high temperature, high pressureargon atmosphere. In some embodiments, the sealed container is initiallycooled in a cooling cabinet after hot isostatic pressing. Following thehot isostatic pressing, the container is transferred from the third cellto the fourth cell via a third moveable shielded isolation door. In thefourth cell, according to some embodiments, the container undergoesfinal cooling. In further embodiments, the container is packaged in acanister for transport and storage.

It will be appreciated by those skilled in the art that changes could bemade to the exemplary embodiments shown and described above withoutdeparting from the broad inventive concept thereof. It is understood,therefore, that this invention is not limited to the exemplaryembodiments shown and described, but it is intended to covermodifications within the spirit and scope of the present invention asdefined by the claims. For example, specific features of the exemplaryembodiments may or may not be part of the claimed invention and featuresof the disclosed embodiments may be combined. Unless specifically setforth herein, the terms “a”, “an” and “the” are not limited to oneelement but instead should be read as meaning “at least one”.

It is to be understood that at least some of the figures anddescriptions of the invention have been simplified to focus on elementsthat are relevant for a clear understanding of the invention, whileeliminating, for purposes of clarity, other elements that those ofordinary skill in the art will appreciate may also comprise a portion ofthe invention. However, because such elements are well known in the art,and because they do not necessarily facilitate a better understanding ofthe invention, a description of such elements is not provided herein.

Further, to the extent that the method does not rely on the particularorder of steps set forth herein, the particular order of the stepsshould not be construed as limitation on the claims. The claims directedto the method of the present invention should not be limited to theperformance of their steps in the order written, and one skilled in theart can readily appreciate that the steps may be varied and still remainwithin the spirit and scope of the present invention.

1. A system for transferring hazardous waste material into a sealablecontainer, the system comprising: a filling nozzle having: a valve bodyhaving a distal end and an outer surface, the valve body including avalve seat proximate the distal end, the outer surface proximate thedistal end being configured to sealingly and removeably couple the valvebody to an inner surface of a filling port of the container, a valvehead having a valve face configured to form a seal with the valve seatin a closed configuration, the valve head configured to allow the valvebody and the container to be fluidly coupled with one another in an openconfiguration, and a valve stem extending axially from the valve headthrough at least a portion of the valve body.
 2. The system of claim 1further comprising: a container configured to sealingly contain thehazardous waste material, the container including the filling port. 3.The system of claim 1 further comprising: a hopper; a first scalecoupled to the hopper and configured to determine an initial hopperweight, a second scale coupled to the container and configured todetermine a container fill weight; and a processor coupled to the firstscale and the second scale and configured to compare the initial hopperweight to the container fill weight.
 4. The system of claim 3, whereinthe hopper includes a volume substantially equal to a volume of thecontainer.
 5. The system of claim 4 further comprising: at least onevibrator coupled to the hopper.
 6. The system of claim 1 furthercomprising: at least one vibrator coupled to a bottom of the container.7. (canceled)
 8. (canceled)
 9. (canceled)
 10. The system of claim 1further comprising: a sensor disposed in the valve head, the sensor isconfigured to determine a level of hazardous material in the container.11. (canceled)
 12. (canceled)
 13. (canceled)
 14. The system claim 1,wherein the valve body includes: a first branch section configured tocouple to a hopper, and a second branch section including the distal endand having a proximal end, the proximal end coupled to a drive mechanismconfigured to move the valve stem.
 15. (canceled)
 16. The system ofclaim 14, wherein the valve stem extends through the proximal end of thesecond branch section, the proximal end including a seal coupled to aportion of the valve stem.
 17. The system of claim 1 further comprising:a vacuum nozzle configured to be in fluid communication with thecontainer.
 18. The system of claim 17, wherein the vacuum nozzle extendsthrough the distal end of the valve body.
 19. The system of claim 18,wherein the vacuum nozzle includes a filter proximate the distal end ofthe valve body. 20-24. (canceled)
 25. The system of claim 1, wherein thevalve head is configured to extend distally from the valve body and intothe container in the open configuration.
 26. (canceled)
 27. (canceled)28. A method of transferring hazardous waste material into a sealablecontainer, the method comprising: coupling an outer surface of a fillingnozzle with an inner surface of a filling port of the container to forma first seal; opening a valve of a filling nozzle to add hazardous wastematerial into the container, the valve being proximate the first seal;closing the valve of the filling nozzle; decoupling the filling portfrom the filling nozzle and inserting a fill plug into the filling port,the fill plug forming a second seal with the inner surface of thefilling port, the second seal being distally spaced from at least aportion of the first seal with respect to the container.
 29. The methodof claim 28, wherein the valve includes: a valve body having a distalend and an outer surface, the valve body including a valve seatproximate the distal end, the outer surface proximate the distal endbeing configured to sealingly and removeably couple the valve body tothe filling port of the container, a valve head having a valve faceconfigured to form a seal with the valve seat in a closed configuration,the valve head configured to allow the valve body and the container tobe fluidly coupled with one another in an open configuration, and avalve stem extending axially from the valve head through at least aportion of the valve body.
 30. The method of claim 28, wherein thecontainer includes an evacuation port.
 31. The method of claim 30,wherein the evacuation port includes an evacuation plug threadablycoupled to the evacuation port, the method further comprising: allowingair and/or gas to pass through the filter and between the evacuationplug and the evacuation port in a filling configuration and a heatingconfiguration; and closing the evacuation port with the evacuation plugin a closed configuration.
 32. (canceled)
 33. The method of claim 28,further comprising: drawing air within the container displaced by thehazardous material through an evacuation nozzle coupled to thecontainer, the evacuation nozzle being in sealed fluid communicationwith the valve body via the container.
 34. (canceled)
 35. The method ofclaim 28, further comprising: weighing a hopper containing the hazardousmaterial to determine an initial hopper weight; weighing the containerwhile adding the hazardous material to determine a container fillweight; and comparing, via a processor, the difference between theinitial hopper weight to the container fill weight.
 36. The method ofclaim 35 further comprising: closing the valve once the container fillweight equals the initial hopper weight; vibrating the hopper via atleast one vibrator while adding the hazardous material to the container;vibrating the container via at least one vibrator coupled to thecontainer while adding the hazardous material to the container;measuring the level of hazardous material in the container via a sensordisposed in the valve head; applying a vacuum to the container before orduring adding of the hazardous material; permanently sealing the fillplug to the filling port; and heating and reducing the volume of thecontainer after permanently sealing the fill plug to the filling port.37-44. (canceled)